Headlamp: Service and Repair

REPAIR PROCEDURE OF HEADLIGHT ASSEMBLY

HINT:
- Use the same procedure for both the RH and LH sides.
- The procedure described below is for the LH side.
- If only the installation area of the headlight assembly is damaged, the repairs described below can be performed inexpensively by using brackets for the repair. This may only be done if the other areas of the headlight assembly are not damaged.

1. INSTALL HEADLIGHT PROTECTOR UPPER RETAINER

HINT:
- If only the installation area of the headlight assembly is damaged, use a bracket for a low-cost repair.
- Ensure that other areas of the headlight assembly are not damaged.







a. Cut off the portion indicated by the hatched lines in the illustration and smooth the surface with sandpaper.

HINT: After cutting off the hatched lines, place the headlight protector upper retainer against the bosses and gradually file away the hatched lines until installation is possible.







b. Install the headlight protector upper retainer with the 2 screws.

2. INSTALL HEADLIGHT PROTECTOR LOWER RETAINER

HINT:
- If only the installation area of the headlight assembly is damaged, use a bracket for a low-cost repair.
- Ensure that other areas of the headlight assembly are not damaged.







a. Cut off the portion indicated by the hatched lines in the illustration and smooth the surface with sandpaper.

HINT: After cutting off the hatched lines, place the headlight protector against the bosses and gradually file away the hatched lines until installation is possible.







b. Install the headlight protector lower retainer with the 2 screws.

3. INSTALL HEADLIGHT NO. 2 PROTECTOR LOWER RETAINER

HINT:
- If only the installation area of the headlight assembly is damaged, use a bracket for a low-cost repair.
- Ensure that other areas of the headlight assembly are not damaged.







a. Cut off the portion indicated by the hatched lines in the illustration and smooth the surface with sandpaper.

HINT: After cutting off the hatched lines, place the headlight protector against the bosses and gradually file away the hatched lines until installation is possible.







b. Install the headlight No. 2 protector lower retainer with the 2 screws.